6s project.ppt
Transcript of 6s project.ppt
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3/ 12/ 2003 CONFIDENTIAL
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Project title
Reduce the NPI pilot run
setup time in SMT lines
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Definition:
The NPI pilot run setup time in SMT lines,which is defined as the total time from SMTdepartment stops building the prior model to SMTdepartment starts to build the first board ofbalance quantity of NPI (except the sampleboards, normally 4pcs).
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0100
200300400
500
600700
800
Mar'04 Apr'04 May'04 Jun'04 Jul'04
U s e
d t i m e
( m i n )
Loading Tape board Sample board W/S Test
Target:360min
678
Primary Metric
742
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Process Mapping
Tape board Pass? Sample board Check Pass?Yes
Yes
No No
Build
Loading Check
Pass?Yes
No
FCTPass?Yes
No
W/S(If necessary)
ICT
Remark: non-value station
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Problem 1 & SolutionItem Problem Root cuase Solution
1
In A26117-01C1 build, Jun.105 min wasted for awaitingmaterials
Communication
2In 1591-719-5-A build, Jun. 80
mins to wait for material.Communication
3
In A26116-01C build, June.60 min to wait for material (use 3160622000AYS toreplace 3160619100AYS).
Communication
leader in time with last informations,and leader makes the last decisionand inform team in time, such as re-schedule NPI for material shortage
4
In C54T02P04 build, June. Westop NPI in tape boardbecause of PCB quality issue.
Communication
prior to SMT loading, start to buildNPI balance quantity withoutsample board result but have the FAreport of sample board from TEdepartment, etc.
Have not the smoothcommunications between internalteam member each other, so weappoint ME colleague to be teamleader for all NPI run, that is, the
relevant team members report to
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The responsibility of NPI team leader
1. Act as the team leader after Prog department held thekick-off meeting of NPI.
2. Push team members to complete his/her departmentaltask and have them to report the status to team leader.
3. Hold the NPI meeting to review team member's progress ifnecessary.4. Make the final decision if there are different opinions
among team members.5. Push Material department to prepare the materials and
inform Prod department to pick up materials from Store. Else,when material shortage or quality issue required 4 hrs toresolve prior to NPI build, team leader needs to inform PCdepartment to re-schedule NPI build.
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The responsibility of NPI team leader(continued)
6. Inform relevant departments to stop NPI or re-scheduleif there are some accidents in NPI process, for example,
material quality issue in NPI process, etc.7. If sample board test failed and TE has submitted the FAreport, team leader needs to inform SMT to build or notaccording to the FA report & team members' suggestion.
8. Summarize the FA (First Article) report and submit toteam members.
9. Hold the close meeting for preparation of massproduction after NPI completed.
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Problem 2 & Solution
Item Problem Root cuase Solution
Tape Board test will be parallel with Sample boardbuild to eliminate the non-value action, that means,
EE & IPQA check the component's orientation,stuffed component and non-stuff location usingaccording to the template or assembly drawing after EE builboard, if no problem found, notify EE to continue tobuild sample board (normally 4pcs), at the sametime, EE & IPQA continue to test the tape board.
However, production run is not allow withoutcompletion of the tape board testing.
1
About 300 minutes average for tape board, but we use 210minutes to check tape boardamong them.
Non-value
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Tape boardCheck orientationstuffed componentnon-stuff location
Check componentvalue
Build sampleboard
Tape board
Check componentvalue
Before:
Current:Build sample
boardCheck orientationstuffed componentnon-stuff location
Problem 2 & Solution (Continued)
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Problem 3 & Solution
Item Problem Root cuase Solution
1. ME draw out the master list of W/S parameters for reference.2. Directly run the 4pcs sampleboards at once and manual solderingif necessary
1 About 80minutes averagefor W/S.
Non-value
(Run a piece of sample board, andthen adjust the relevant parametersof WS machine, afterward, runanother sample board, and thenadjust the relevant parameters again,
and run other 2pcs sample board likethis.)
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AssemblyRun the first
sample board
Adjustparameters
of W/S
Before:
Adjustparameters
of W/S
Run theSecond
sample board
Current:
AssemblyDirectly run the 4pcs
sample boards atonce.
Adjust parameters accordingto the master list drew by ME
dept.
Problem 3 & Solution (Continued)
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Problems 4 & Solution
FA target < 500pcs components need 1 hrs500---1500pcs components need 1.5 hrs>1500pcs components need 2 hrs
Item Problem Root cuase Solution
1
About 120minutesaverage for teststation.
Non-value
(We must have the result of sampleboards test and then start to buildNPI boards, actually, somedefectives are not impact SMT tobuild, such as open, short,etc.)
If the sample board test fail, TEanalyze them and submit the FAreport to team. If the defects justlike open/short, team leader willinform SMT to build according to theFA report, at the same time, TEcontinue to re-debug & re-test tilltest ass.
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Test fail
Before:
FA Re-debug Re-test Test pass Inform SMTto build
Current:
Test fail FA
Re-debug Re-test Test pass
Inform SMTto build
Problems 4 & Solution (Continued)
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Problems 5 & Solution
SMT changes line as soon as they complete
the 4pcs sample boards, if TE department has notthe golden sample to debug test program/fixtureprior to NPI build.
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The micro process mapping
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NPI setup time in SMT lines
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300400
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Mar'04 Apr'04 May'04 Jun'04 Jul'04 Aug'04 Sep'04 Oct'04 Nov'04 Dec'04
U s e
d t i m e
( m i n )
Loading Tape board Sample board W/S Test
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736742678
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